基于Moldflow的带金属嵌件电机齿轮盖注塑工艺优化  

Optimization of injection molding process for motor gear cover with metal inlay based on Moldflow

作　　者：刘云飞 龙泉 戴宇 熊建武[1,3,4] 王得胜 LIU Yunfei;LONG Quan;DAI Yu;XIONG Jianwu;WANG Desheng(Hunan Industry Polytechnic,Changsha 410006,China;Bosch Automotive Parts(Changsha)Co.,Ltd.,Changsha 410100,China;Xiangtan Vocational College of Science and Technology,Xiangtan 411100,China;Shaoyang General Aviation Vocational College,Shaoyang 422999,China)

机构地区：[1]湖南工业职业技术学院,长沙410006 [2]博世汽车部件(长沙)有限公司,长沙410100 [3]湘潭科技职业学院,湖南湘潭411100 [4]邵阳通航职业技术学院,湖南邵阳422999

出　　处：《工程塑料应用》2024年第7期94-100,130,共8页Engineering Plastics Application

摘　　要：汽车雨刮电机齿轮盖采用注射成型技术,内嵌齿轮盖中的3根金属嵌件起到导通电流的作用。在注射成型过程中要确保各金属嵌件有一定的间距,以保证电机正常工作。为了验证设计的方案是否满足设计要求,采用模流分析软件Moldflow对齿轮盖注射成型过程进行分析,以准确掌握金属嵌件的变形情况。初始方案仿真计算结果显示,注射成型后用于接地的嵌件31在XY平面内变形量过大,可能存在搭接短路风险,不满足设计要求。针对嵌件31变形量过大的问题,分析可能的原因,从注射成型工艺参数和嵌件定位方案两方面进行优化。在满足设计要求前提下,通过正交试验法获得最优的模具温度和熔体温度,仿真结果表明:将注射成型工艺参数中的模具温度调整为80℃,熔体温度调整为265℃,嵌件31的变形量减少27.3%;将嵌件31的定位方式更换成穿孔式定位,可有效增加嵌件的定位可靠性。两种优化方案共同实施后,嵌件31的最大变形量从0.55 mm降低到0.05 mm,变形量减小90.9%,满足设计指标要求,提升了设计产品的可靠性。The motor gear cover of automobile wiper system is generally made by injection molding,and 3 pieces of metal inlays in it play a role in conducting current.During the injection molding process,it is necessary to ensure that there is a certain distance between the metal inlays to ensure the normal operation of the motor.In order to verify whether the design scheme meets the design requirements,the mold flow analysis software Moldflow was used to analyze the injection molding process of the gear cover,accurately grasping the deformation situation of the metal inlay.The simulation calculation result of initial scheme shows that the deformation of inlay 31 for grounding is too large and cannot meet design requirement,which leads to the risk of short circuit from overlapping between two inlays.Aiming at the problem of excessive deformation of inlay 31,the possible reasons were analyzed,and the injection molding process parameters and insert positioning scheme were optimized.Under the premise of meeting the design requirements,the optimal mold temperature and melt temperature were obtained by orthogonal test.The results show that the deformation of inlay 31 is reduced by 27.3%when the mold temperature is 80℃and melt temperature is 265℃.Through-hole positioning method is changed in positioning of inlay 31,which increase the positioning reliability of inlay 31.After the implementation of two optimization scheme,the maximum deformation is reduced from 0.55 mm to 0.05 mm,which is reduced by 90.9%and can meet design index requirement.

关 键 词：电机齿轮盖 嵌件 模流分析 变形量 工艺参数 

分 类 号：TH164[机械工程—机械制造及自动化]